Process for the manufacturing of surface elements

ABSTRACT

A process for the manufacturing of surface elements ( 1 ) which comprises a decorative upper layer ( 2 ) and a supporting core ( 5 ). A supporting core ( 5 ) with a desired format is manufactured and provided with an upper side ( 1 ′) and a lower side ( 4 ). The upper side ( 1 ′) of the supporting core ( 5 ) is provided with a décor , by for example printing, which décor ( 2 ′) is positioned after a predetermined fixed point on the supporting core ( 5 ). The upper side ( 1 ′) of the supporting core ( 5 ) is provided with a protecting, at least partly translucent, wear layer ( 2 ″) by for example spray coating, roller coating, curtain coating and immersion coating or by being provided with one or more sheets of α-cellulose impregnated with thermosetting resin or lacquer.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a process for the manufacturing ofsurface elements with a decorative upper surface of which the decorativeelements have an considerably improved matching of the décor betweenadjacent surface elements.

2. Description of the Related Art

Products clad with thermosetting laminate is common in many areasnowadays. They are mostly used where the demands on abrasion resistanceare high, and furthermore where resistance to different chemicals andmoisture is desired. As examples of such products floors, floorskirtings, table tops, work tops and wall panels can be mentioned.

The thermosetting laminate most often consist of a number of base sheetswith a decor sheet placed closest to the surface. The decor sheet can beprovided with a pattern by desire. Common patterns usually visualisedifferent kinds of wood or mineral such as marble and granite.

One common pattern on floor elements is the rod pattern where two ormore rows of rods of, for example wood, is simulated in the décor .

The traditional thermosetting laminate manufacturing includes a numberof steps which will result in a random matching tolerance of up to ±5mm, which is considered too great. The steps included in themanufacturing of a laminate floor is: printing decor on a paper ofα-cellulose, impregnating the decorative paper withmelamine-formaldehyde resin, drying the decorative paper, laminating thedecorative paper under heat and pressure together with similarly treatedsupporting papers, applying the decorative laminate on a carrier andfinally sawing and milling the carrier to the desired format. All thesesteps in the manufacturing will cause a change in format on the decorpaper. It will, therefore, be practically impossible to achieve adesired match of patterns between adjacent elements causing greatamounts of wasted laminate. Naturally, this waste is not desirable, asthe thermosetting laminate is a rather costly part of a laminate floor.

SUMMARY OF THE INVENTION

It has, through the present invention, been made possible to overcomethe above mentioned problems and provide a surface element with adecorative surface where the decorative pattern between differentsurface elements with matching of the decorative pattern can beobtained. The invention relates to a process for the manufacturing ofsurface elements which surface elements comprise a decorative upperlayer and a support core. The surface elements may be used as floor,wall or ceiling boards. The invention is characterised in that:

i) A supporting core with a desired format is manufactured and providedwith an upper side and a lower side.

ii) The upper side of the support core is then provided with a décor ,by, for example, printing. The décor is positioned after a predeterminedfixing point on the support core.

iii) The upper side of the supporting core is then provided with aprotecting, at least partly translucent, wear layer by, for example,spray coating, roller coating, curtain coating and immersion coating orby being provided with one or more sheets of α-cellulose impregnatedwith thermosetting resin or lacquer.

The décor is suitably achieved by digitisation of an actual archetype orby partly or completely being created in a digital media. The digitiseddécor is stored digitally in order to be used as a control function andoriginal, together with possible control programs, when printing thedécor.

The décor may accordingly be obtained by making a high resolution orselected resolution digital picture of the desired decor. This issuitably made by means of a digital camera or scanner. The most commondécor will of course be different kinds of wood and minerals likemarble, as these probably will continue to be preferred surfacedecoration in home and public environments. It is, however, possible todepict anything that is visible. The digitised version of the décor isthen edited to fit the size of the supporting core. It is also possibleto rearrange the décor in many different ways, like changing colourtones, contrast, dividing the décor into smaller segments and addingother decorative elements. It is also possible to completely create thedécor in a computer equipped for graphic design. It is possible tocreate a simulated décor so realistic that even a professional will havegreat problems in visually separating it from genuine material. Thismakes it possible to make for example floor boards with an almostperfect illusion of a rare kind of wood, like ebony or rose wood andstill preserving trees under threat of extermination.

The digital décor is used together with guiding programs to control aprinter. The printer may be of an electrostatic type or an ink-jet typeprinter. Most often the colours yellow, magenta, cyan and black will besufficient for the printing process, but in some cases it might beadvantageous to add white. Some colours are difficult to achieve usingthe colours yellow, magenta, cyan, black and white whereby the colourslight magenta and light cyan may be added. It is also possible to add socalled spot colours where specific colour tones are difficult to achieveor where only certain parts of the colour spectrum with intermixingshades is desired. The resolution needed is much depending on the décorthat is to be simulated, but resolutions of 10-1500 dots per inch (dpi)is the practical range in which most décors will be printed. Undernormal conditions a resolution of 300-800 dpi is sufficient whencreating simulations of even very complex decorative patterns and stillachieve a result that visually is very difficult to separate from thearchetype without close and thorough inspection.

The digitally stored décor can also be used together with supportprograms when guiding other operations and procedures in themanufacturing process. Such steps in the operation may includeprocedures like identification marking, packaging, lacquering, surfaceembossing, storing and delivery logistics as well as assemblyinstructions.

It is advantageous to manufacture the supporting core in the desired enduser format and to provide it with edges suited for joining beforeapplying the décor and wear layer, since the amount of waste thereby isradically reduced. The décor matching tolerances will also be improvedfurther by this procedure.

The main part of the support core is suitably constituted by a particleboard or a fibre board. It is, however, possible to manufacture the corethat at least partly consists of a polymer, such as, for example,polyurethane or a polyolefin, such as, polyethylene, polypropylene orpolybutene. A polymer based core can be achieved by being injectionmoulded or press moulded and can be given its shape by plastic mouldingand does, therefore, not require any abrasive treatment. A polymer basedcore may also contain a filler in the form of a particle or fibre oforganic or inorganic material, which, besides its use as a cost reducingmaterial, also can be used to modify the mechanical characteristics ofthe core. As an example of such suitable fillers can be mentioned;cellulose or wood particles, straw, starch, glass, lime, talcum, stonepowder and sand. The mechanical characteristics that may be changed are,for example, viscosity, thermal coefficient of expansion, elasticity,density, fire resistance, moisture absorption capacity, acousticproperties, thermal conductivity, flexural and shearing strengths aswell as softening temperature.

The upper surface, i.e. the surface that is to be provided with décor,is suitably surface treated before the printing. Such surface treatmentwill then incorporate at least one of the steps, ground coating andsanding. It is also possible to provide the surface with a structurethat matches the décor that is to be applied.

The translucent wear layer is suitably constituted by a UV- or electronbeam curing lacquer such as an acrylic,epoxy, or maleimide lacquer. Thewear layer is suitably applied in several steps with intermediate curingwhere the last one is a complete curing while the earlier ones are onlypartial. It will hereby be possible to achieve thick and plane layers.The wear layer suitably includes hard particles with an average particlesize in the range 50 nm-150 μm. Larger particles, in the range 10 μm-150μm, preferably in the range 30 μm-150 μm, are used to achieve abrasionresistance while the smaller particles, in the range 50 nm-30 μm,preferably 50 nm-10 μm is used for achieving scratch resistance. Thesmaller particles is hereby used closest to the surface while the largerones are distributed in the wear layer. The hard particles are suitablyconstituted of silicon carbide, silicon oxide, α-aluminium oxide and thelike. The abrasion resistance is hereby increased substantially.Particles in the range 30 mm-150 mm can for example be sprinkled onstill wet lacquer so that they at, least partly, become embedded in thefinished wear layer. It is therefore suitable to apply the wear layer inseveral steps with intermediate sprinkling stations where particles areadded to the surface. The wear layer can hereafter be cured. It is alsopossible to mix smaller particles, normally particle sizes under 30 μmwith a standard lacquer. Larger particles may be added if a gellingagent or the like is present. A lacquer with smaller particles issuitably used as top layer coatings, closer to the upper surface. Thescratch resistance can be improved by sprinkling very small particles inthe range 50 nm-1000 nm on the uppermost layer of lacquer. Also these,so called nano-particles, can be mixed with lacquer, which with isapplied in a thin layer with a high particle content. Thesenano-particles may besides silicon carbide, silicon oxide andα-aluminium oxide also be constituted of diamond.

According to one embodiment of the invention, the translucent wear layeris constituted of one or more sheets of α-cellulose which areimpregnated with melamine-formaldehyde resin. These sheets are joinedwith the core under heat and pressure whereby the resin cures. It is,also in this embodiment, possible to add hard particles with an averageparticle size in the range 50 nm-150 μm. Larger particles, in the range10 μm-150 μm, preferably 30 μm-150 μm, is foremost used to achieveabrasion resistance while the smaller of the particles, in the range 50nm-30 μm, preferably 50 nm-10 μm, is used to achieve scratch resistance.The smaller particles is hereby used on, or very close to, the topsurface while the larger particles may be distributed in the wear layer.Also, here the particles advantageously are constituted of siliconcarbide, silicon oxide, α-aluminium oxide, diamond or the like of whichdiamond, for cost reasons only is used as particles smaller than 1 μm.The sheets of α-cellulose is hereby suitably pressed together with therest of the surface element in a continuous belt press with two steelbelts. The pressure in the press is hereby suitable 5-100 Bar,preferably 20-80 Bar. The temperature is suitably in the range 140-200°C. It is also possible to utilize a discontinuous process where a numberof surface elements can be pressed in a so called multiple-opening pressat the same time. The pressure is then normally 20-150 Bar, preferably70-120 Bar, while the temperature suitably is 120-180° C., preferably140-160° C.

The décor on the surface elements is suitably constituted by a number ofdécor segments with intermediate borders, which borders, on at least twoopposite edges coincide with intended, adjacent surface elements.

It is also desirable to provide the surface elements with a surfacestructure intended to increase the realism of the décor of the surfaceelements. This is suitably achieved by positioning at least one surfacestructured matrix, forming at least one surface structure segment on acorresponding décor segment or number of décor segments on the decoratedsurface of the surface element in connection to the application of wearlayer. This matrix is pressed towards the wear layer whereby this willreceive a surface with structure that enhances the realism of the décor.

When simulating more complex patterns, like wood block chevron patternor other décors with two or more divergent and oriented décors, it issuitable to use at least two structured matrixes which forms onestructure segment each. The structure segment are here independent fromeach other in a structure point of view. The surface structure segmentsare intended to at least partly but preferably completely match thecorresponding décor segments of the décor. The surface structuresegments are accurately positioned on the décor side of the surfaceelement in connection to the application of the wear layer, and ispressed onto this whereby the wear layer is provided with a surfacestructure where the orientation of the structure corresponds to thedifferent directions in the décor.

One or more matrixes preferably forms the surface of one or morerollers. The surface element is then passed between the roller orrollers and counter stay rollers, with the décor side facing thestructured rollers. The structured rollers are continuously ordiscontinuously pressed towards the décor surface of the surfaceelement.

Rollers containing two or more matrixes, is suitably provided with acircumference adapted to the repetition frequency of change of directionin the décor.

It is also possible to apply the structure matrixes on the surface of apress belt. The surface element is then passed between the press beltand a press belt counter stay under continuous or discontinuous pressurebetween the structured press belt and the press belt counter stay.

It is, according to one alternative procedure, possible to have one ormore matrixes form the structure surface of one or more static mouldswhich momentary is pressed towards the decorative side of the surfaceelement.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to one embodiment of the invention, particularlycharacteristic décor segments such as borderlines between simulatedslabs, bars, blocks or the like and also knots, cracks, flaws and grainwhich is visually simulated in the décor, are stored as digital data.Said data are used for guiding automated engraving or pressing toolswhen providing said characteristic décor segments with a suitablesurface structure, and that said engraving tool or pressing tool issynchronised via the predetermined fixing point on the surface element.

The process described in the present application, for manufacturingsurface elements is very advantageous from a logistic point of viewsince the number of steps when achieving a new décor is radicallyreduced. It is, according to the present invention possible to usedigitally created or stored data for directly printing the décor on asurface element by using a ink-jet printer or a photo-static printer.The so-called set up time will thereby be very short, whereby even veryspecial customer requirements may be met at a reasonable cost. It isaccording to the present invention possible to manufacture, for example,a world map in very large format, stretching over a great number ofsurface elements without any disrupting deviations in décor matching, tomainly the same cost as bulk produced surface elements. Since the décormay be handled digitally all the way to the point of being applied tothe surface of the core, set up times will be practically non-existentwhile at the same time a high degree of automation will be practicable.It is also possible to automatically provide the surface elements withidentification and orientation marking which would make the installationof complex décors, like world maps in the example above, much easier.This has so far been impossible.

The décor on the surface elements may be processed as follows;

i) A segmentation pattern is selected, the segmentation comprising atleast two décor segments on each surface element. The shape, as seenfrom above, of the surface element is hereby selected from the group;triangular, quadratic, rectangular, heptagonal, pentagonal and octagonalwhile the shape of the segments is selected from the group triangular,quadratic, rectangular, heptagonal, pentagonal, octagonal, circular,elliptical, perturbed and irregular.

ii) A segment décor is then selected for each segment. The segment décoris selected from the group; digitised and simulated depiction ofdifferent kinds of wood, minerals and stone, different kinds of fabric,art work and fantasy based décor.

iii) Each selection is made on a terminal where the selections emanatesfrom a data base and that the selection is visualised via the terminal.

The décor is preferably achieved by digitisation of an actual archetypeor by partly or completely being created in a digital media. Thedigitised décor is preferably stored digitally in order to be used as acontrol function and original, together with control programs andselection parameters, when printing the décor.

The dimensions of the surface to be covered by surface elements issuitably entered into the terminal and support programs calculates aninstallation pattern. The installation pattern calculation is suitablyalso used for printing an assembly instruction. In order to visualisethe selection the installation pattern calculation is possibly used forprinting a miniaturised copy of the calculated installation with theselected pattern and décor. The dimensions of the surface to be coveredby surface elements is suitably entered into the terminal and that thatsupport programs further calculates décor and segmentation patternmatching between the surface elements.

The selections is preferably also used, together with support programsfor controlling further steps in the manufacturing procedure selectedfrom the group; identification marking, positioning marking, packaging,lacquering, surface embossing, storing and delivery logistics.

An algorithm is suitably used for guiding the positioning of the décorsegments and segmentation pattern so that a décor segment from onesurface element may continue on an adjoining surface element. Thecontrol program is suitably used, together with décor data and selectionparameters, for applying matching identification on the surfaceelements.

Surface elements manufactured as described above is suitably used as afloor covering material where the demands on stability and scratch andabrasion resistance is great. It is, according to the present invention,also possible to use the surface elements as wall and ceiling decorativematerial. It will however not be necessary to apply thick wear layercoatings in the latter cases as direct abrasion seldom occurs on suchsurfaces.

The invention is described further in connection to an enclosed FIGURE,embodiment examples and schematic process descriptions showing differentembodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Accordingly, the FIGURE shows parts of a surface element 1 whichincludes an upper decorative layer 2, edges 3 intended for joining, alower side 4 and a supporting core 5. The process is initiated bymanufacturing a supporting core 5 with a desired format and edges 3intended for joining. The supporting core 5 is further provided with anupper side 1′ suited for printing and a lower side 4. The upper side 1′of the supporting core 5 is then provided with a décor 2′ by printing,utilizing an ink-jet printer. The décor 2′ is oriented after apredetermined fixing point on the supporting core 5. The upper side 1′of the supporting core 5 is then provided with a protecting translucentwear layer 2″ through curtain coating. The supporting core 5 isconstituted by particle board or fibre board. The translucent wear layer2″ is constituted by a UV-curing acrylic lacquer which is applied inseveral steps with intermediate curing, of which the last one is acomplete curing while the earlier ones are only partial curing. The wearlayer 2″ also includes hard particles of α-aluminium oxide with anaverage particle size in the range 0.5 μm-150 μm.

A surface structured matrix is positioned and pressed towards the décorside of the surface element 1 before the final curing of the acryliclacquer whereby the surface of the wear layer 2″ receives a surfacestructure 2′″ which enhances the realism of the décor 2′.

It is also possible to utilise two or more surface structured matrixes,each forming a structure segment, between which the structure isindependent, which will make it possible to simulate the surfacestructure of, for example, wood block chevron pattern décor.

A supporting polymer and filler based core is manufactured in thedesired format and is provided with an upper side, a lower side andedges provided with joining members, such as tongue and groove. Theupper side of the supporting core is then sanded smooth after which aprimer is applied. A décor is then applied on the upper side by means ofa digital photo-static five colour printer. The colours are magenta,yellow, cyan, white and black. The décor is positioned from apredetermined fixing point in form of a corner of the supporting core,while the décor direction is aligned with the long side edge initiatingfrom the same corner.

The basis for the décor is stored as digital data. This digital data hasbeen achieved by digitising a number of wood grain patterns with adigital camera. A number of rectangular blocks with a fixed width, butof varying length is selected and parted from the digital wood grainpictures. The width of the rectangular blocks is selected so that threeblock widths equals the width of a supporting core. The digital image ofthe wood blocks are then classified after wood grain pattern and colourso that a number of groups is achieved. The groups are; fair wood witheven grain, dark wood with even grain, fair wood with knots and flaws,dark wood with knots and flaws, fair cross-grained wood and finally darkcross-grained wood. Each group contains five different blocksimulations. An algorithm is feed into a computer which is used for theguiding of the printing operation so that the simulated wood blocks isdigitally placed in three longitudinal rows and mixed so that twosimilar wood blocks never is placed next to each other. The algorithmwill also guide the position of the latitudinal borderlines between thesimulated wood blocks so that they are unaligned with more than oneblock width between adjacent rows. It will also guide the latitudinalposition of the borderlines so that it either aligns with the shorteredges of the supporting core or is unaligned with more than one blockwidth. Another printer, also guided by the computer, is utilised forprinting a running matching number on the lower side short side edges.The décor will hereby continue longitudinally over the surface elementsand a perfect matching is obtained when the surface elements are placedin numerical order.

A basic layer of UV-curing acrylic lacquer is then applied by means of arollers. Particles with an average particle size in the range 150 μm isthen sprinkled onto the still wet basic layer, whereby the main layer ofUV-curing acrylic lacquer is applied by spray coating. The two layers oflacquer are then partly cured using UV-light whereby the viscosity ofthe lacquer increases. A top layer of UV-curing acrylic lacquer with anadditive in the form of hard particles with an average size of 2 μm, isthen applied by means of a roller. Hard particles with an average sizeof 100 nm is then sprinkled on top of the wet top layer, whereby thelacquer is partly cured with UV-light so that the viscosity increases.The still soft lacquer is then provided with a structure in the form ofnarrow, small, elongated recesses, simulating the pores of the wood.This will increase the realism of the decor. This is achieved byalternate between two different structured roller per row of simulatedwood blocks. The structure of the rollers simulates even wood grain andcross-grained wood respectively. The rollers are alternately pressedtowards the lacquered surface while it passes. The positioning of therollers are guided via the digitally stored data used for printing thedécor as well as the fixing point used there.

It is according to one alternative embodiment possible to utilise one ormore static moulds with surface structure which momentary is pressedtowards the décor side.

Especially characteristic décor segments such as borderlines betweenslabs, bars, blocks or the like and also knots, cracks, flaws and grainwhich is visually simulated in the décor, is suitably stored as digitaldata. This data is achieved by processing selected parts of thesimulated wood blocks so that guiding data is achieved. Said data isthen used for guiding an automated robot provided with an engraving toolor a press mould which provides the surface of the lacquer with astructure that matches said characteristic décor segments. The operationis also here synchronised via by the predetermined fixing point on thesupporting core.

The lacquer is then completely cured with UV-light to desired strength,whereby the finished surface elements may be inspected by the naked eyeor by a digital camera supported by a computer. The surface elements arethen packed in batches and provided with identification markings.

The process above will make it possible to have a completely customerdriven manufacturing where even very small quantities may be producedwith the same efficiency as bulk manufacturing. Even though only onedécor is described in connection to the process scheme above, it becomesclear to anyone skilled in the art, that a décor is changed very easilyin the process. All of the important steps of the manufacturing such asprinting, structuring, inspection, packaging and identification markingmay be controlled and supervised by central processing data. This willmake it logistically possible to manufacture customer designed decors.Such a process is exemplified as follows;

The customer utilises a database via Internet or at a local dealer. Itis also possible for another operator utilise a database. The databasecontains samples and/or reduced resolution copies of a great variety ofstandard decors which can be combined after predetermined parameters.

The parameters may, for example, concern a single surface element where,for example, chevron pattern, diamond pattern and block pattern may bethe choices of décor segmentation. It will here be possible to select aset of different simulations to randomly or by selected parameters fillthe segments, for example, marble, birch and mahogany. The customer mayalso add an inlay from a design of his own which is digitised andprocessed, preferably automatically, to a desired format and resolution.

The parameters may alternatively include décor segments that requiresthe space of several surface elements, for example a map over the world.The parameters may here further include fading of the larger design to asurrounding decor, surrounding frame of other décor etc.

The customer enters the measurements of the surface that is to becovered by the surface elements. The customer then makes selections fromthe database and is able to see his selection as a completed surface,either on screen or by printing. The visualisation program used, issuitably also used for calculating installation pattern and presentinginstallation instructions with identification numbers on surfaceelements and where to cut the elements in order to make a perfect match.The surface elements may also be provided with removable matching lineson the decorative side making matching of décor between adjacent rowseasier. The customer or dealer may then confirm his order via electronicmail where the pattern and décor is reduced to a code sequence and theorder can be the direct input to the computer guiding the manufacturingprocess as described above. The customer and/or dealer data follows themanufacturing process all the way to packaging and a fully customerguided manufacturing process is achieved.

A supporting fibre board based core is manufactured in the desiredformat and is provided with an upper side, a lower side and edges. Theupper side of the supporting core is then sanded smooth after which awhite primer is applied. A décor is then applied on the upper side bymeans of a digital ink-jet four colour printer. The colours are magenta,yellow, cyan and black. The décor is positioned from a predeterminedfixing point in form of a corner of the supporting core, while the décordirection is aligned with the long side edge initiating from the samecorner.

The basis for the décor is stored as digital data. This digital data hasbeen achieved by digitising a number of wood grain patterns with adigital camera. A number of rectangular blocks with a fixed width, butof varying length are selected and parted from the digital wood grainpictures. The width of the rectangular blocks is selected so that threeblock widths equals the width of a finished surface element. The digitalimage of the wood blocks are then joined digitally to form a rectangularsurface of a specified size, for example, 200×1200 mm. A selected amountof such combinations of different blocks are designed as described aboveso that a number of slightly different rectangular surfaces is achieved.The printer, or preferably a set of printers are positioned so that adesired number of rectangular décor surfaces with a specifiedintermediate distance is printed on the supporting core. Theintermediate distance between the rectangular surfaces is the distanceneeded for parting and moulding of edges. The décor printer or printersare also used for printing fixing points at predetermined positions.Another printer, also guided by the computer, is utilised for printingan identity code on the lower side of each intended finished surfaceelement.

A basic layer of UV-curing acrylic lacquer is then applied by means ofrollers. Particles with an average particle size in the range 75 μm isthen sprinkled onto the still wet basic layer, whereby a top layer ofUV-curing acrylic lacquer with an additive in the form of hard particleswith an average size of 2 μm, is applied by means of a roller. Hardparticles with an average size of 100 nm is then sprinkled on top of thewet top layer, whereby the lacquer is partly cured with UV-light so thatthe viscosity increases. The still soft lacquer is then provided with astructure in the form of narrow, small, elongated recesses, simulatingthe pores of the wood. This will increase the realism of the décor. Thisis achieved by pressing rollers towards the lacquered surface while itpasses. The positioning of the rollers are guided via the digitallystored data used for printing the décor, as well as the fixing pointused there when more complex and completely matching surface structuresas described together with process scheme 1 is desired.

The lacquer is then completely cured with UV-light to desired strength,whereby the finished surface element is cut into the predeterminedformats which are provided with edges with joining functionality aremoulded by milling. The cutting and edge moulding process is positionedfrom fixing point printed close to the decor. The surface elements maythen be inspected by the naked eye or by a digital camera supported by acomputer. The surface elements are then packed in batches and providedwith identification markings.

It is, according to an alternative procedure in the process, possible tocut and mould the edges at an earlier stage in the process. It issuitable to apply and cure a protecting layer of lacquer on top of theprinted décor followed by cutting and moulding of the edges. Theremaining and main part of the wear layer is then applied as describedin connection to process scheme 1 or 2 above.

The process above will make it possible to have a customer initiatedmanufacturing where even very small quantities may be produced with thesame efficiency as bulk manufacturing. Even though only one décor isdescribed in connection to the process scheme above, it becomes clearanyone skilled in the art, that décors is changed very easily in theprocess. All of the important steps of the manufacturing such asprinting, structuring, inspection, packaging and identification markingmay be controlled and supervised by central processing data.

The invention is also described through embodiment examples.

EXAMPLE 1

A supporting core of medium density fibre board were sanded smooth. Alayer of primer lacquer were applied on top of the fibre board. Theprimer were cured after which a décor was printed on top of the primer.

The build up of a wear layer was then initiated by applying 30 g/m² ofUV-curing acrylic lacquer by means of roller coating. 20 g/m² of hardparticles made of α-aluminium oxide with an average particle size of 70μm were sprinkled on the still sticky lacquer. The lacquer was thenexposed to a predetermined energy amount of UV-light so that it curedonly partly and the viscosity was increased. Another 30 g/m² ofUV-curing acrylic lacquer was then roller coated onto the alreadyapplied layer after which another 20 g/m² of α-aluminium oxide particleswith an average particle size of 70 μm were sprinkled on the stillsticky second coating. The lacquer was then exposed to a predeterminedenergy amount of UV-light so that it cured only partly and the viscositywas increased. Three layers of UV-curing acrylic lacquer was thenapplied by roller coating with intermediate partial curing as a above.Each of the three layers had a surface weight of 20 g/m². The hardparticles were completely embedded in the lacquer after the three layerswere applied and a plane upper wear layer surface was achieved.

A top coating procedure was then initiated. A first layer of UV-curingacrylic topcoat lacquer was applied by means of a roller coater on topof the previous, partly cured, layers. The topcoat lacquer contained 10%by weight of hard particles of α-aluminium oxide with an averageparticle size of 10 μm. The first layer was applied to a surface weightof 10 g/m². The topcoat lacquer was then exposed to a predeterminedenergy amount of UV-light so that it cured only partly and the viscositywas increased. A second layer of the topcoat lacquer was then appliedand partly cured as described above. The wear layer was then providedwith a surface structure by means of a surface structured roller. Athird layer of the topcoat formulation was then applied on top of thestructured wear layer. Also the third layer of top coat was applied to asurface weight of 10 g/m². The wear layer was then exposed to apredetermined energy amount of UV-light so that it cured completely.

The wear layer was then tested for abrasion resistance according to ISO4586/2-88, where an IP value of 7100 turns was obtained. An IP value of7100 turns is fully sufficient for floor covering materials with mediumto heavy traffic like hotel lobbies, hallways and the like.

EXAMPLE 2

A supporting core of medium density fibre board were sanded smooth. Alayer of primer lacquer were applied on top of the fibre board. Theprimer were cured after which a decor was printed on top of the primer.The build up of a wear layer was then initiated by applying 30 g/m² ofUV-curing acrylic lacquer by means of roller coating. 20 g/m² of hardparticles made of α-aluminium oxide with an average particle size of 70μm were sprinkled on the still sticky lacquer. The lacquer was thenexposed to a predetermined energy amount of UV-light so that it curedonly partly and the viscosity was increased. Another 30 g/m² ofUV-curing acrylic lacquer was then roller coated onto the alreadyapplied layer after which another 20 g/m² of α-aluminium oxide particleswith an average particle size of 70 μm were sprinkled on the stillsticky second coating. The lacquer was then exposed to a predeterminedenergy amount of UV-light so that it cured only partly and the viscositywas increased. Three layers of UV-curing acrylic lacquer was thenapplied by roller coating with intermediate curing as a above. Each ofthe three layers had a surface weight of 20 g/m². The hard particleswere completely embedded in the lacquer after the three layers wereapplied and a plane upper wear layer surface was achieved. Also theuppermost of the three layers of lacquer was cured to a desiredviscosity.

A second décor layer was then printed on top of the wear layer. Thesecond décor layer, which was identical to the first décor closest tothe core, was oriented and positioned so that it completely matched thefirst décor.

The build up of an upper wear layer was then initiated by applying 30g/m² of UV-curing acrylic lacquer by means of roller coating. 20 g/m² ofhard particles made of α-aluminium oxide with an average particle sizeof 70 μm were sprinkled on the still sticky lacquer. The lacquer wasthen exposed to a predetermined energy amount of UV-light so that itcured only partly and the viscosity was increased. Another 30 g/m² ofUV-curing acrylic lacquer was then roller coated onto the alreadyapplied layer after which another 20 g/m² of α-aluminium oxide particleswith an average particle size of 70 μm were sprinkled on the stillsticky second coating. The lacquer was then exposed to a predeterminedenergy amount of UV-light so that it cured only partly and the viscositywas increased. Three layers of UV-curing acrylic lacquer was thenapplied by roller coating with intermediate curing as a above. Each ofthe three layers had a surface weight of 20 g/m². The hard particleswere completely embedded in the lacquer after the three layers wereapplied and a plane upper wear layer surface was achieved.

A top coating procedure was then initiated. A first layer of UV-curingacrylic topcoat lacquer was applied by means of a roller coater on topof the previous, partly cured, layers. The topcoat lacquer contained 10%by weight of hard particles of α-aluminium oxide with an averageparticle size of 10 μm. The first layer was applied to a surface weightof 10 g/m². The topcoat lacquer was then exposed to a predeterminedenergy amount of UV-light so that it cured only partly and the viscositywas increased. A second layer of the topcoat lacquer was then appliedand partly cured as described above. The wear layer was then providedwith a surface structure by means of a surface structured roller. Athird layer of the topcoat formulation was then applied on top of thestructured wear layer. Also the third layer of top coat was applied to asurface weight of 10 g/m². The wear layer was then exposed to apredetermined energy amount of UV-light so that it cured completely.

The wear layer was then tested for abrasion resistance according to ISO4586/2-88, where an IP value of 13500 turns was obtained. An IP value of13500 turns is fully sufficient for floor covering materials withheavier traffic like airports, railway stations and the like. The secondlayer of décor and wear layer will add abrasion resistance withouthaving obtained an unwanted hazy effect in the decor.

EXAMPLE 3

A supporting core of medium density fibre board were sanded smooth. Alayer of primer lacquer were applied on top of the fibre board. Theprimer were cured after which a decor was printed on top of the primer.

The build up of a wear layer was then initiated by applying 15 g/m² ofUV-curing acrylic lacquer by means of roller coating. 20 g/m² of hardparticles made of α-aluminium oxide with an average particle size of 70μm were sprinkled on the still sticky lacquer. The lacquer was thenexposed to a predetermined energy amount of UV-light so that it curedonly partly and the viscosity was increased. One layer of UV-curingacrylic lacquer was then applied by roller coating and was partiallycured as above. The layer had a surface weight of 40 g/m². The hardparticles were embedded in the lacquer after the layer of lacquer wasapplied and a mainly plane upper wear layer surface was achieved.

A top coating procedure was then initiated. A first layer of UV-curingacrylic topcoat lacquer was applied by means of a roller coater on topof the previous, partly cured, layers. The topcoat lacquer contained 10%by weight of hard particles of α-aluminium oxide with an averageparticle size of 10 μm. The first layer was applied to a surface weightof 10 g/m². The topcoat lacquer was then exposed to a predeterminedenergy amount of UV-light so that it cured only partly and the viscositywas increased. The wear layer was then provided with a surface structureby means of a surface structured roller. A second, final layer of thetopcoat formulation was then applied on top of the structured wearlayer. Also the second layer of top coat was applied to a surface weightof 10 g/m². The wear layer was then exposed to a predetermined energyamount of UV-light so that it cured completely.

The wear layer was then tested for abrasion resistance according to ISO4586/2-88, where an IP value of 3100 turns was obtained. An IP value of3100 turns is fully sufficient for floor covering materials with lighttraffic like bedrooms, living rooms and the like.

The invention is not limited to the embodiments shown as these can bevaried in different ways within the scope of the invention. It is forexample possible to use so-called overlay sheets of α-celluloseimpregnated with thermosetting resin instead of acrylic lacquer in theprocess described in connection to process scheme 1 and in particular inthe process described in connection to process scheme 2. These sheets ofa-cellulose which are impregnated with melamine-formaldehyde resin isjoined with the supporting core through heat and pressure, whereby theresin cures. The wear resistance may also in this embodiment be improvedby adding hard particles in the range 50 nm-150 μm to the wear layer.

What is claimed is:
 1. A process for the manufacturing of surfaceelements which surface elements comprise a decorative upper layer and asupporting core; said process comprising: i) providing a supporting corewith an upper side; ii) providing the upper side of the supporting corewith a décor, which décor is achieved by at last one of digitizing anactual archetype and at least partly creating said décor in a digitalmedium, which décor is positioned after a predetermined fixing point onthe supporting core, iii) protecting the upper side of the supportingcore with an at least partly translucent, wear layer, iv) enhancing thedécor by accurately applying a surface structured matrix against thewear layer utilizing the predetermined fixing point to create a surfacestructure on the wear layer.
 2. A process according to claim 1, whereinthe décor is achieved by digitization of an actual archetype or bypartly or completely being created in a digital media, which digitizeddécor is stored digitally in order to be used as a control function andoriginal when printing the décor.
 3. A process according to claim 2,wherein at least parts of the digitized décor is used, together withsupport programs for controlling further steps in the manufacturingprocedure.
 4. The process according to claim 3, wherein said furthersteps in the manufacturing procedure include at least one ofidentification marking, packaging, lacquering, surface embossing,storage logistics, delivery logistics, and assembly instructions.
 5. Theprocess according to claim 2, further comprising forming the décor byusing controlled programs in combination with the digitized décor.
 6. Aprocess according to claim 1, wherein the supporting core ismanufactured in the desired end user format and provided with edgesintended for joining before applying the décor and the wear layer.
 7. Aprocess according to claim 1, wherein the supporting core is at leastone of selected from the group consisting of a particle board and afibre board.
 8. A process according to claim 1, wherein at least partsof the supporting core comprise a polymer.
 9. A process according toclaim 8, wherein the supporting core comprises a polymer which alsocontains a filler in the form of a particle or fibre of organic orinorganic material.
 10. The process according to claim 8, wherein saidpolymer comprises a polyurethane or a polyolefin.
 11. The processaccording to claim 10, wherein said polyolefin is at least one selectedfrom the group consisting of polyethylene, polypropylene andpolybutylene.
 12. A process according to claim 1, wherein thetranslucent wear layer consists of a UV curing or electron beam curingresin or lacquer.
 13. A process according to claim 12, furthercomprising applying the wear layer in several steps with intermediatecuring, of which the last applying comprising a curing step which is acomplete curing while the intermediate curing step(s) are only partialcuring step(s).
 14. A process according to claim 12, wherein the wearlayer also comprises hard particles with an average particle size in therange 50 nm-150 μm.
 15. A process according to claim 14, wherein anupper portion of the wear layer is provided with hard particles in therange 50 nm-30 μm, while an inner portion of the wear layer is providedwith hard particles in the range 10 μm-150 μm.
 16. A process accordingto claim 15, wherein the hard particles are at least one selected fromthe group consisting of silicon oxide, silicon carbide, α-aluminiumoxide and diamond.
 17. The process according to claim 15, wherein theparticles in the upper portion of the wear layer are in the range of 50nm-10 μm, while the particles in the inner portion of the wear layer arein the range 30 μm-150 μm.
 18. A process according to claim 14, whereinthe hard particles are at least one selected from the group consistingof silicon oxide, silicon carbide and α-aluminium oxide.
 19. The processaccording to claim 12, in which said resin or lacquer is one selectedfrom the group consisting of acrylic, epoxy and maleimide.
 20. A processaccording to claim 1, wherein the translucent wear layer consists of atleast one sheet of α-cellulose impregnated with melamine-formaldehyderesin.
 21. A process according to claim 20, wherein the wear layer isjoined with the supporting core through heat and pressure, whereby theresin cures.
 22. A process according to claim 20, wherein the wear layeralso comprises hard particles with an average particle size in the range50 nm-150 μm.
 23. A process according to claim 22, wherein an upperportion of the wear layer is provided with hard particles in the range50 nm-30 μm, while an inner portion of the wear layer is provided withhard particles in the range 10 μm-150 μm.
 24. A process according toclaim 23, wherein the hard particles are at least one selected from thegroup consisting of silicon oxide, silicon carbide, α-aluminium oxideand diamond.
 25. A process according to claim 22, wherein the hardparticles are at least one selected from the group consisting of siliconoxide, silicon carbide and α-aluminium oxide.
 26. The process accordingto claim 23, wherein the particles in the upper portion of the wearlayer are in the range of 50 nm-10 μm, while the particles in the innerportion of the wear layer are in the range of 30 μm-150 μm.
 27. Aprocess according to claim 1, wherein the décor on the surface elementsis constituted by a number of décor segments with intermediate borders,which borders, on at least two opposite edges of a surface elementcoincide with borders on intended adjoining floor elements.
 28. Aprocess according to claim 1, wherein said at least one surfacestructured matrix forms at least one surface structure segment and ispositioned on the decorative side of the surface element during the stepin the process where the wear layer is applied on the surface elementand is pressed towards the wear layer whereby the wear layer receives asurface with a structure that enhances the realistic impression of thedécor.
 29. A process according to claim 28, wherein at least one matrixforms the structured surface of at least one roller whereby the surfaceelement is passed between the structured surface roller and a matchingcounter stay under continuous or discontinuous pressure between therollers and the counter stay.
 30. A process according to claim 29,wherein the roller equipped with two or more matrixes has acircumference adapted to a repetition distance in the variation ofdirection in the décor.
 31. A process according to any of the claims 28,wherein a specially characteristic décor segments is visually simulatedin the décor is stored as digital data, that said data is used forguiding automated engraving or pressing tools when providing saidcharacteristic décor segments with a suitable surface structure, andthat said engraving tool or pressing tool is synchronised via thepredetermined fixing point on the surface element.
 32. The processaccording to claim 31, wherein the specially characteristic décorsegments are at least one selected from the group consisting ofborderlines between simulated slabs, bars or blocks; knots, cracks,flaws and grain.
 33. A process according to claim 1, further comprisingproviding at least two surface structured matrixes, which each matrixforms one surface structure segment, which segments are independent fromeach other concerning structure, and that said surface structuresegments are intended to coincide with corresponding pattern segments inthe decor, positioning said surface structured matrices on thedecorative side of the surface element during the steps in the processwhere the wear layer is provided, and pressing the matrices toward thewear layer whereby the wear layer receives a surface structurecorresponding to different pattern segments in the décor.
 34. A processaccording to claim 33, wherein one or more matrixes forms the structuredsurface on one or more press belts, whereby the surface element ispassed between the press belts and counter stays, with the decorativeside facing the press belts, during continuous or discontinuous pressurebetween the press belts and counter stays.
 35. A process according toclaim 33, wherein at least one matrix forms the structured surface on atleast one static moulds which is pressed towards the decorative surfaceof the surface element.
 36. The process according to claim 1, whereinthe protection of the upper side of the supporting core is achieved byat least one coating step selected from the group consisting of spraycoating, roller coating, curtain coating, and immersion coating.
 37. Theprocess according to claim 1, wherein protecting of the upper side ofthe supporting core is achieved by providing at least one sheet ofα-cellulose impregnated with thermosetting resin or lacquer as the atleast partly translucent, wear layer.
 38. The process according to claim1, wherein the décor is formed by printing.
 39. The process according toclaim 1, wherein said core is formed of fiberboard.